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Thread: 2003 K1200GT - any tips on fuel filter change?

  1. #16
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    Another question before I button this up. The tank's front bolts that you just loosen were beyond stiff. A lot of leverage needed to loosen them and once moving groaned like an old rusty bolt.

    What to do? WD40 on it, motor oil, Aluminum anti seize are on my list. The other bolts on the back side were smooth and little problem. Thanks for comments.
    2003 K1200GT

  2. #17
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by jrmull View Post
    Another question before I button this up. The tank's front bolts that you just loosen were beyond stiff. A lot of leverage needed to loosen them and once moving groaned like an old rusty bolt.

    .
    I never had to loosen them. I would lift the back of the tank and slide the tank off of the front mounts.
    Is this the mount you're talking about.

    left front tank mount.jpg
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  3. #18
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by jrmull View Post
    Quick release was not much fun. .
    Did you replace the quick disconnects? If not, and you need new Viton orings PM me and I'll mail you a few.

    If you replaced the QDs, save one of the old ones.
    It makes for an easy fast way to drain the tank.

    IMG_0238.jpg


    IMG_0095.jpg
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  4. #19
    Debbie's Servant Lee's Avatar
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    Forgot to mention the drain hose clamps. The type of clamp for the drain hoses is not a big deal because they are not under pressure.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  5. #20
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    Yes, those are the bolts on the front of the tank which are extremely hard to loosen. I have them loose now but not smoothly turning. They are binding. On the other notes of draining the gas, that was a mess. I have it empty now for work.

    Any suggestions on the dead fly in the air intake?

    I did pick up some one-time small clamps at the auto store. Ready to button this up.

    thanks
    2003 K1200GT

  6. #21
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by jrmull View Post
    Any suggestions on the dead fly in the air intake?
    I don't know if it's a problem.
    Sometimes it's better to pretend it never happened

    Between my K1200RS and my wife's K1200RS I changed quite a few air filters, and I'm guessing one or two bugs dropped down into the airbox when changing those filters.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  7. #22
    Registered User GTRider's Avatar
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    Fly, what fly??

    If you haven’t put the tank back in place, it’s a small matter to pop the filter cover, pull the filter, and stick a vacuum cleaner nozzle in there. I normally do that as part of my filter replacement routine anyway. And if you don’t get him out I wouldn’t be too worried about it; I don’t think flies are particularly abrasive.

    Best,
    DG
    DGerber
    1983 R80ST — 1984 R80 G/S PD — 1993 R100GS — 2004 K1200GT w/Hannigan S/C — 2010 K1300GT
    BMWMOA#52184, AMA#271542, IBA#138

  8. #23
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    Thank you for the dead fly comments. Midwest got socked with winter storm so I haven't finished closing up the tank. I have a little vacuum to give it an attempt.

    I did find smaller 3/8 clamps at Menards that are stainless steel. When reduced to size, it looks pretty bad visually. See picture. I won't see it in the tank but on the outside connections, it looks bad. The excess tail gets long too. I got some crimp clamps the right size at the auto store and will use them. Keep extras on hand for another trip under the tank.

    I can see why the dealer is using crimping types. More compact, more professional looking.
    Attached Images Attached Images
    2003 K1200GT

  9. #24
    Registered User GTRider's Avatar
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    Quote Originally Posted by jrmull View Post
    Thank you for the dead fly comments. Midwest got socked with winter storm so I haven't finished closing up the tank. I have a little vacuum to give it an attempt.

    I did find smaller 3/8 clamps at Menards that are stainless steel. When reduced to size, it looks pretty bad visually. See picture. I won't see it in the tank but on the outside connections, it looks bad. The excess tail gets long too. I got some crimp clamps the right size at the auto store and will use them. Keep extras on hand for another trip under the tank.

    I can see why the dealer is using crimping types. More compact, more professional looking.
    You don’t want that worm-drive type of clamp—it will damage the hose by the time it’s clamped tight enough to withstand fuel pressure. You want the smooth band-style clamps—either screw-type or crimp-on (Oetiker) clamps. If you’re not having any luck sourcing them at your dealer you could try a NAPA store, Amazon, or McMaster-Carr.

    https://www.amazon.com/s?k=Fuel+inje...f=nb_sb_noss_2

    https://www.mcmaster.com/hose-clamps

    Best,
    DG
    DGerber
    1983 R80ST — 1984 R80 G/S PD — 1993 R100GS — 2004 K1200GT w/Hannigan S/C — 2010 K1300GT
    BMWMOA#52184, AMA#271542, IBA#138

  10. #25
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by GTRider View Post
    You don’t want that worm-drive type of clamp—it will damage the hose by the time it’s clamped tight enough to withstand fuel pressure.
    DG
    I think he's talking about the small vent or drain hoses??
    In his picture he has the correct type of clamp on the fuel lines.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  11. #26
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    It lives. Filled a half gallon and pump activated. Started up fine.

    I ended up using the screw band on the venting tubes. The small tube are non pressured and I didn't mash them tight. The main filter tubes were replaced and I used Max screw type that have a solid band. I was happy with that and future removal easy. I was more comfortable using screwdriver pressure to tighten that a crimping tool. For the vent tubes, it was tight using the Menard threaded band. It was stainless steel and those venting tubes need to be pull to work on the filter. That was my approach. I appreciate the warnings DG is advising. Only part not replaced was the screen for $70. I will send that one back to the store.

    On the vent tube outside the tank, they also have to be removed frequently to pull the tank. I couldn't get my crimping tool in there. The screw type worked for minimal pressure on the tubes. One worry is the band extends over the top of the fuel line. I need to keep it from rubbing. I will figure out something or go back to crimping. I have a box of crimping clamps but thanks for the offer on sourcing parts.

    I dug out from another shed the shop vac. Improvised using my oil fuel to get deep into the air box. No dead fly found. Maybe my vacuum process turned it to dust. Well worth the try. I was quite proud of my invention.

    Somewhere, I misplaced that tank washer and rubber grommet that Lee was talking about. %@@$%% That wasted a couple hours. I found the washer but missing the thin rubber grommet. I kept putting on the tank, losing the big rubber insert. Tank back off, search, find, repeat. Grommet pops out, tank back off, search, find, repeat. New swear words invented. I see someone prior used rubber cement to hold the center grommet in place. I tried tape. Eventually it worked less a thin rubber grommet on the outside bolt.

    Oh and I scratch the tank top.

    Still have some clean up to do. Replace the quick release Orings, Test ride to look for leaks or panel warning lights. Order a couple tank grommets.

    Thanks for all the assistance. John
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    2003 K1200GT

  12. #27
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by jrmull View Post
    On the vent tube outside the tank, they also have to be removed frequently to pull the tank. I couldn't get my crimping tool in there. The screw type worked for minimal pressure on the tubes. One worry is the band extends over the top of the fuel line. I need to keep it from rubbing. I will figure out something or go back to crimping.
    You can get by without a clamp on those two vent lines outside the tank.
    The hose has a snug fit on the metal tube and their's plenty of overlap.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  13. #28
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    Ugh. Bike won't start. 2003 K1200GT 26k miles

    I finished changing the fuel and air filter this week. Replaced the quick disconnect ORings. I had it running several times this week checking leaks, etc and it was running with out panels naked.

    I put the panels back on and it started and idled fine for about 2-3 mins. Then sputtered and shut off. I was going to let it warm up for awhile but it didn't get that far. I figured low/out of fuel since I had just a small amount in and the yellow low fuel light was on anyway.

    I filled the tank to 1/4 on the gas gauge. About 2 gallons premium. It won't start. I smell some fuel out the exhaust. Low fuel light is off now with all the gas in the tank.

    Waited another couple hours. Still won't start. I hear the fuel pressurize and no warning lights. Just cranks. I guess I will try the battery disconnect tomorrow is if that resets the computer.

    Worst case, find that diagnostic tool.

    It is on the center stand. Side stand it up, Kill switch ready, Neutral gear. Clutch in on start. Good battery power and crank speed. I am thinking running out of fuel, wacked the computer codes. Has it in some shutoff mode. Beat me.
    2003 K1200GT

  14. #29
    Registered User GTRider's Avatar
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    When you turn on the switch do you hear the fuel pump energize briefly? And of you do, please repeat the test only with the fuel cap open and your ear down there listening for fuel squirting/splashing inside the tank. Please report back...

    Best,
    DG
    DGerber
    1983 R80ST — 1984 R80 G/S PD — 1993 R100GS — 2004 K1200GT w/Hannigan S/C — 2010 K1300GT
    BMWMOA#52184, AMA#271542, IBA#138

  15. #30
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by jrmull View Post
    I hear the fuel pressurize and no warning lights. Just cranks.
    Sounds like the two electrical connectors are in place.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

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